Method of making pillows

ABSTRACT

An improved method for making three- or four-way taper pillows from a web of soft compressible material that is folded into a batt and encased in a pillow tick. This is accomplished by folding the web along first fold lines to produce a multi-ply web having a plurality of superimposed plies located between opposite edges while positioning some of the fold lines between the opposite edges such that there are a greater number of plies along the center of the multi-ply web then at the opposite edges and subsequently folding the multi-ply web along second fold lines extending perpendicular to the opposite sides of the multiply web to produce a pillow batt having a plurality of layers each having a plurality of plies. The batt is then enclosed in a pillowed tick by compressing the peripheral edge to produce a completed pillow. In one embodiment, a three-way tapered pillow is produced by locating all of the fold lines along one edge of the layers in a common plane while the fold lines along the opposite edge are staggered relative to each other and in an alternative embodiment a four-way taper is produced by staggering the fold lines of the layers along both edges.

July 4, 1972 United States Patent Willis [54] METHOD OF MAKING PILLOWS [57] ABSTRACT An improved method for making threeor four-way taper pillows from a web of soft compressible material that is folded into a batt and encased in a pillow tick. This is accomplished by folding the web along first fold lines to produce a multi-ply web having a plurality of superimposed plies located between opposite edges while positioning some of the fold lines 1 mm 1 w dw n. .l 3 n -l ADhm r m N n w kw n i 1 FA 1] 2 2 7 22 l [l 5 3 3 a 76 7 74 2 b2 51.9 7 653 1 B2 w 1 5 H w I F W 1 F R 3 "2 5 my m5 r n a u e S L k U .mF 1] 2 00 5 55 l [.l

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s mumbom m bntanvilb References Cited peripheral edge to produce a completed pillow.

all of the fold lines along one edge of the layers in a plane while the fold lines along the opposite edge are d in an alternative embodiduced by staggering the fold lines of the layers along both edges.

In one embodiment, a three way tapered pillow is produced by locating common staggered relative to each other an ment a four-way taper is pro win 3 m R2 5m u n n 0 mm m S mm 0 T mm 0 N mm & E u" l m m m w m P mm mm S m l W mm M 6 9 u h m W 8. d m S 1. .55 D BS Vd l E raw n 20 N 67 f H .m$ 28 mm mD nm E W 94 m mm m w 77 r! 33 PA 11 Claims, 5 Drawing Figures METHOD OF MAKING PILLOWS BACKGROUND OF THE INVENTION The present invention relates to an improved method for making batt-filled pillows.

Because of the extreme shortage of down and the increased cost of manufacturing down-filled pillows, the industry has recently looked towards various substitutes for the conventional down in the forming of pillows. One type of material which has been used extensively in recent years is what is commonly referred to as batt and a pillow formed from this material is shown in my U.S. Pat. No. 3,290,704.

In batt-filled pillows, an elongated web or mat of a soft, resilient, compressible material of substantially uniform thickness and density is folded upon itself to produce the batt having a plurality of layers of the web. The batt is then enclosed in a pillow tick and is usually compressed while the pillow tick is sewn or otherwise placed in encompassing relation around the batt.

In the formation of pillows in this manner, the edges of the pillow usually have substantial thickness and thereby detract from the overall comfort and appearance. Furthermore, the batt does not conform to the shape of the tick and the resultant pillow is lumpy.

SUMMARY OF THE INVENTION The present invention contemplates the formation of a batt pillow in which the pillow has a major thickness at the central portion thereof which tapers to a minimum thickness from the central portion towards a plurality of adjacent edges. The

. method of making the rectangular pillow includes the steps of moving a web of compressible material in one direction and folding the web along spaced parallel fold lines at a first station to produce a multi-ply web having a plurality of superimposed plies. The fold lines along opposite sides of the multi-ply web are staggered relative to each other to locate more plies at the center than at either side.

The multi-ply web is then moved in a second direction parallel to the opposite sides and folded along spaced fold lines extending substantially nonnal to the sides of the multiply web to produce a batt having a plurality of superimposed layers. In one embodiment, the fold lines of the layers are staggered relative to each other along both of the remaining two edges to produce a pillow having a maximum thickness at the central portion and tapering to a reduced thickness at all four of the edges when the batt is compressed and encased in a pillow tick.

In an alternative embodiment, the fold lines of the layers are staggered along one edge and are located in a substantially common plane along a fourth edge to produce a pillow having a cross-sectional wedge-shaped dimension between the latter two edges.

More specifically, the pillow batt is formed by continuously moving a conveyor along a path, feeding an endless web of compressible material through a guide, reciprocated between extreme positions above the conveyor in a direction perpendicular to the path of movement of the conveyor, and selectively reversing the direction of movement of the guide between the extreme positions so as to stagger the fold lines of the multi-ply web adjacent opposite sides thereof. The multiply web is then compacted and fed through a second guide which is reciprocated between extreme positions above a second conveyor to fold the multi-ply web into a plurality of superimposed layers interconnected along fold lines perpendicular to the sides of the multi-ply web. The multi-ply web is intermittently severed adjacent the second guide and the second conveyor is intermittently moved so as to produce a plurality of individual batts.

In one embodiment, the fold lines on both of the edges of the layers are staggered relative to each other to produce a completed pillow having a high center crown which tapers in all four directions to the outer edges when the batt is compressed and encased in a tick. In an alternative embodiment,

all of the fold lines along one edge of the layers are located in a substantially common vertical plane while the fold lines along the opposite edge are staggered relative to each other to produce a substantially wedge-shaped pillow between the latter edges.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF DRAWINGS FIG. 1 is a perspective view of a pillow constructed in accordance with the method of the present invention;

FIG. 2 is a perspective view of exemplary apparatus for performing the method;

FIG. 3 is a schematic illustration of the configuration of the web as viewed along line 3-3 of FIG. 2;

FIG. 4 is a view of the completed batt as viewed along line 4-4 of FIG. 2; and

FIG. 5 is a view similar to FIG. 4 showing a slightly modified embodiment of the invention.

DETAILED DESCRIPTION While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail two specific embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.

The method of the present invention contemplates forming a pillow of the type illustrated in FIG. 1 which includes a pillow batt 12 compressed and enclosed in a pillow tick l4 and in which the completed pillow has a central crown portion 15 of a maximum thickness which tapers to a reduced thickness towards both pairs of opposed edges 16 and 18. The batt enclosed in the pillow tick is formed by the method of the present invention so as to have shape corresponding substantially to the shape of the pillow tick 14 to create a pillow which is substantially devoid of any lumps and corresponds in appearance to a conventional down-filled sleeping pillow. Construction of the pillow is described and claimed in more detail in my copending application, Ser. No. 121,102, entitled Improved Pillow Construction, filed March 4, 1971 and assigned to the assignee of the present invention.

In the embodiment illustrated in FIGS. 1, 3 and 4, the pillow batt 12 includes a plurality of layers 20 of a multi-ply web 19 that is folded along spaced fold lines 22 and 24. As more clearly shown in FIG. 4, the fold lines 22 defining one of the edges 16 for the finished pillow are staggered relative to each other so as to have a greater number of layers 20 along the central portion of the batt than there are along the left-hand edge 16, as viewed in FIG. 4. Likewise, the fold lines 24 on the right-hand side, as viewed in FIG. 4, are staggered relative to each other. While the fold lines have been shown to be located in two substantially common vertical planes, it will be appreciated that the staggering arrangement can be varied to produce the desired taper from the central portion 16 of the pillow towards the opposite edges 16.

The multi-ply web defining the respective layers 20 is illustrated in cross-sectional view in FIG. 3 and includes a thin, unitary web of compressible intermingled fibers which is folded along spaced fold lines 32 and 34 to produce a plurality of plies 36 located in superimposed relation to each other and extending between the opposed edges 18 of the finished pillow. As shown in FIG. 3, the respective fold lines 32 are again staggered relative to each other and the fold lines 34 are likewise staggered relative to each other to locate a greater number of plies along the central portion of the multi-ply web 19 than along either of the opposite sides 36.

The method for producing the pillow batt 12 comprises continuously feeding an endless web 30 of intermingled fibers of soft, resilient, compressible material through a first reciprocating guide 40 that includes a frame 42 supporting a pair of spaced rollers 44. The guide mechanism is reciprocated above an endless conveyor 46 between two extreme positions that respectively define the opposite sides 36 of the continuous web 19. The apparatus further includes means for reversing the direction of the guide mechanism adjacent the extreme positions and also selectively reversing the direction of the guide mechanism at locations between the extreme positions above the conveyor 46. For this purpose, first and second reversing mechanisms 50 and 52 are disposed in the path of movement of the reciprocating guide mechanism 40.

In considering a sequence of operation for the guide mechanism 40, and assuming that the guide mechanism is moving towards the right as viewed in FIG. 2, the reversing mechanism 50 would reverse the guide mechanism 40 at a location spaced inwardly from the outer side or edge 36 of the multiply web such that the next fold line for the endless sheet 30 would be located at a superimposed relation of the remainder of the fold lines 34b. Moving in the opposite direction, the reversing mechanism 52 would then reverse the movement of the switching mechanism at a point to locate the subsequent fold line 32b at a location spaced inwardly from the left-hand side or edge 36 of the multi-ply web. Upon a subsequent movement of the guide mechanism to the right as viewed in FIG. 2, the reversing mechanism 50 would reverse the direction of movement at a location to produce a fold line 34a which would be located in a common vertical plane with previous fold lines 34a as well as the side 36 of the multi-ply web. Thus, summarizing briefly, the reversing mechanisms 50 and 52 would respectively alternately reverse the guiding mechanism above the sides of the multi-ply web and altemately at, a location spaced inwardly from the sides 36 adjacent each end of the path of travel for the guide mechanism 40.

The resulting web 19 will therefore include a plurality of superimposed plies 36 of the web with the central portion having a greater number of plies than either of the two sides. Since it is desirable to have the conveyor 46 moving continuously while the web 30 is being deposited thereon, it will be appreciated that the edge 56 of the web will be deposited at an angle extending diagonally of the direction of travel of the conveyor 46. However, by feeding the web 30, through suitable conveying means (not shown), at a rapid rate along the first direction and moving the conveyor 45 considerably slower in the second direction, the acute angle between the edge 56, defining the edges of successive plies of web will be relatively small. Since the web is extremely thin and compressible, such small acute angle between respective edges of superimposed plies will not be objectionable.

The multi-ply'web 19 having the plurality of superimposed plies is then passed between a pair of driven compression rolls 60, one of which may be the idler or drive roll for the conveyor 46 and the compressed web 19 is then fed to a second guide mechanism 62 which may be similar in construction to the first reciprocating guide mechanism 40. The second guide mechanism is reciprocated between extreme positions defining the remaining two edges 18 of the finished pillow and is again reversed at the extreme positions by suitably reversing mechanism 64 and 66. In forming the pillow batt shown in FIGS. 3 and 4, the reversing mechanisms 64 and 66 again alternately reverse the guide mechanism 62 at the extreme edges and subsequently at a location between the extreme edges so as to produce the staggered relation of the fold lines 22 and 24 shown in FIGS. 2 and 3.

After a predetermined number of layers of web have been located above each other in the manner shown in FIG. 2, the multi-ply web 19 may then be severed by suitable cutting means, schematically illustrated at 70, which may be actuated by a timer or any other means. Since the cutting mechanism per se, forms no part of the invention, the detailed description thereof does not appear to be necessary. Suffice it to say that the multi-ply web 19 is intermittently severed to produce a plurality of individual batts 12 that are collected on a further endless conveyor 72 which may be intermittently actuated by the sametiming mechanism as that of the cutter 70.

The completed batts 12 are subsequently enclosed in the tick or casing 14 in any suitable manner, such as by having the casing in two plies which are sewn together around the peripheral edge defined by the opposed pairs of edges 16 and 18. While the batts are enclosed in a pillow tick they are compressed to produce the finished pillow shown in FIG. 1. In the finished pillow the two sides 36 of the multi-ply web 19 define two edges while the opposite two edges are defined by fold lines 22 and 24.

A slightly modified embodiment of the present invention is disclosed in FIGS, when taken in conjunction with FIGS. 2 and 3, shows a method in which one cross-sectional dimension of the pillow between the opposite edges 16 is substantially wedge-shaped in configuration. This wedge-shaped configuration is obtained by arranging all of the fold lines 24a in a substantially common vertical plane on the conveyor 72 while the opposite fold lines 22a are staggered in a manner previously described in connection with the fold lines 22. With this arrangement the edge of the pillow defined by the fold lines 24a will have a thickness which is substantially equal to the thickness of the central portion or crown 15. Such a pillow would serve a dual function of acting as a sleeping pillow when one edge, defined by fold lines 22a, is utilized and acting as a reading pillow of substantial firmness when utilizing the opposite edge, defined by the fold lines 24a.

Thus, the present invention provides a simple and efficient expedient for producing pillows of the type disclosed in the above mentioned copending application.

I claim:

1. A method of making a rectangular pillow batt comprising the steps of moving a web of compressible material in one direction; folding said web at a first station to produce a multiply web having a plurality of plies with the fold lines along opposite edges of said multi-ply being staggered relative to each other; moving said multi-ply web in a second direction perpendicular to said first direction and folding said multi-ply web along spaced fold lines substantially normal to the previous fold lines to produce a batt having a plurality of superimposed layers with the fold lines of said layers along one edge being staggered relative to each other to produce a batt having a maximum thickness at the central portion and tapering to a reduced thickness towards at least three edges when said batt is encased in a pillow tick.

2. A method as defined in claim 1, including the further step of arranging all of the fold lines of the layers in a substantially common plane along a fourth edge of said batt.

3. A method as defined in claim 1, including the further step of staggering the fold lines along a fourth edge of said batt.

4. A method as defined in claim 1, including the step of feeding said web through a guide mechanism located above the conveyor; reciprocating said guide mechanism between extreme position above said conveyor; selectively reversing the direction of movement of said mechanism intermediate said extreme positions; and depositing said web on a conveyor moving in a second direction to locate some of the fold lines of the plies of the multi-ply web intermediate the extreme positions of the reciprocating mechanism.

5. A method as defined in claim 4, including the stepof guiding said multi-ply web through a second guide mechanism; reciprocating said second guide mechanism between extreme positions defining opposite edges of said batt; and selectively reversing the second guide means at locations intermediate said extreme positions to produce some fold lines spaced from said edges.

6. A method as defined in claim 4, including the step of portion tapering to a reduced thickness towards at least three edges.

9. A method of producing a pillow batt which comprises folding a compressible fibrous web of material along spaced fold lines to produce a multi-ply web having a plurality of superimposed plies located between opposite edges; positioning said plies such that there are a greater number of plies along the center of said multi-ply web than at opposite edges; and folding said multi-ply web along fold lines extending between said edges to produce a pillow batt having a plurality of layers each having a plurality of plies of a web.

10. A method as defined in claim 9, in which said web is 

1. A method of making a rectangular pillow batt comprising the steps of moving a web of compressible material in one direction; folding said web at a first station to produce a multi-ply web having a plurality of plies with the fold lines along opposite edges of said multi-ply being staggered relative to each other; moving said multi-ply web in a second direction perpendicular to said first direction and folding said multi-ply web along spaced fold lines substantially normal to the previous fold lines to produce a batt having a plurality of superimposed layers with the fold Lines of said layers along one edge being staggered relative to each other to produce a batt having a maximum thickness at the central portion and tapering to a reduced thickness towards at least three edges when said batt is encased in a pillow tick.
 2. A method as defined in claim 1, including the further step of arranging all of the fold lines of the layers in a substantially common plane along a fourth edge of said batt.
 3. A method as defined in claim 1, including the further step of staggering the fold lines along a fourth edge of said batt.
 4. A method as defined in claim 1, including the step of feeding said web through a guide mechanism located above the conveyor; reciprocating said guide mechanism between extreme position above said conveyor; selectively reversing the direction of movement of said mechanism intermediate said extreme positions; and depositing said web on a conveyor moving in a second direction to locate some of the fold lines of the plies of the multi-ply web intermediate the extreme positions of the reciprocating mechanism.
 5. A method as defined in claim 4, including the step of guiding said multi-ply web through a second guide mechanism; reciprocating said second guide mechanism between extreme positions defining opposite edges of said batt; and selectively reversing the second guide means at locations intermediate said extreme positions to produce some fold lines spaced from said edges.
 6. A method as defined in claim 4, including the step of compressing said web before it is folded into layers.
 7. A method as defined in claim 5, including the step of intermittently severing said web to produce a plurality of individual batts.
 8. A method as defined in claim 1, including the step of enclosing said batt in a pillow tick to compress said batt and produce a pillow having a maximum thickness at the central portion tapering to a reduced thickness towards at least three edges.
 9. A method of producing a pillow batt which comprises folding a compressible fibrous web of material along spaced fold lines to produce a multi-ply web having a plurality of superimposed plies located between opposite edges; positioning said plies such that there are a greater number of plies along the center of said multi-ply web than at opposite edges; and folding said multi-ply web along fold lines extending between said edges to produce a pillow batt having a plurality of layers each having a plurality of plies of a web.
 10. A method as defined in claim 9, in which said web is folded in a manner that the opposed edges of said multi-ply web define opposed edges of said batt and at least some of the fold lines of said multi-ply web define a second pair of opposed edges for said batt, the further step of positioning at least some of said fold lines of said layers at a location spaced from said second pair of opposed edges.
 11. A method as defined in claim 10, in which all of the fold lines along one of said second pair of edges are located in a substantially common vertical plane. 